CHEMICAL
INEOS Chlor Increases Productivity and Efficiency
Using Emerson’s PlantWeb® Digital Architecture
RESULTS
•Increased productivity and efficiency have contributed
€1.3 Million annually
•Centralized control room has improved manning
by 20%
APPLICATION
Installing centralized control room at site with multiple plants.
CUSTOMER
INEOS Chlor is one of the largest Chlor-Alkali producer in Europe and a
global leader in chlorine derivatives. The Runcorn site, in the UK, is
INEOS Chlor’s largest site.
CHALLENGE
The plants at the INEOS Chlor Runcorn site vary in age, with several
having been built in the 1960’s and 70’s. These assets had, until 10
years ago, been operated by panel instrumentation or in some cases,
very early technology computer control systems. Each plant had its
own control room and associated operators.
Even though the site is heavily integrated, each plant was run largely
as a separate entity with limited communication and co-operation.
In 1997, it was clear that an investment strategy to re-instrument the
plant control systems was required. Part of the long term strategy
was to increase the site effectiveness and bring about efficiencies by
installing a centralized control room. A major challenge for INEOS
Chlor was to find a supplier that understood the need for a long term,
developing relationship, rather than treating each project individually.
SOLUTION
Emerson Process Management was chosen by INEOS Chlor as its
automation supplier because of the scalability and adaptability of
the DeltaV™ digital automation system and the knowledge and
experience available from Emerson as an alliance partner. This
alliance has remained in place for over 10 years and has proven to be
a significant factor in the development and exploitation of
automation systems at the Runcorn site.
For more information:
www.EmersonProcess.com/DeltaV
“Our closeworking relationship
with Emerson Process
Management has been a key
enabler in making the
changeover to a
centralized control room as
smooth as possible,without
any loss of production.”
Paul Young
Automation Manager, INEOS Chlor
CHEMICAL
The long term strategic plan was to convert the plant to Emerson’s
®
PlantWeb digital plant architecture and integrate individual control
rooms into a centralized location for the site. The centralized control
room, which replaced the five traditional control rooms, has space
available for further expansion. The site rationalization has enabled
manning to be improved by over 20%.
Key to the success of the project has been to develop a single look
and feel to the operating DCS environment. As individual plants
have been converted to the DeltaV system and control moved to
the centralized location, production rates have been driven up as a
result of this and other improvement works. The contribution from
the centralization project in terms of increased productivity and
efficiency are calculated at around €1.3 Million and other benefits
include greater co-ordination and co-operation between the plants.
Emerson’s DeltaV system provides the process control and the
®
embedded AMS Suite: Intelligent Device Manager software
communicates with the intelligent field devices enabling
configuration, calibration and diagnostic tests to be performed from
a single workstation. The AMS Device Manager audit trail
automatically maintains detailed records of device maintenance
activities, including calibration records, confirming that field
instruments and valves are properly installed and configured,
contributing to increased plant reliability.
This major upgrade project has been executed without any
unscheduled interruptions to operations, or extended shutdowns.
This is seen as amajor success for the teamat INEOS Chlor since a
project of this nature is normally assessed as attaching the highest
level of risk to plant operation and start-up.
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purposes only, and while every effort has been made to ensure
their accuracy, they are not to be construed as warranties or
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